Antimicrobial copper oxide nanoparticle coated masks and methods for producing the same

Abstract

Methods of producing composite articles and composite articles are disclosed herein. A method of producing a composite article includes providing a nonwoven fabric substrate having a surface. In some embodiments, the method may include electrospinning a nylon solution on the surface of the nonwoven fabric substrate to coat and/or impregnate the nonwoven fabric substrate with a nylon fiber.

1 . A method of producing a composite article, the method comprising:
 providing a nonwoven fabric substrate having a surface;   electrospinning a nylon solution on the surface of the nonwoven fabric substrate to coat and/or impregnate the nonwoven fabric substrate with a nylon fiber; and   electrospraying a modified copper oxide nanoparticle onto a surface of the nylon fiber to covalently link the modified copper oxide nanoparticle and the nylon fiber.   
     
     
         2 . The method according to  claim 1 , wherein the nonwoven fabric substrate is a meltblown nonwoven fabric. 
     
     
         3 . The method according to  claim 1 , wherein the nonwoven fabric substrate is a spunbond nonwoven fabric. 
     
     
         4 . The method according to  claim 1 , wherein the nonwoven fabric substrate is a meltblown-spunbound composite. 
     
     
         5 . The method according to  claim 1 , wherein the nonwoven fabric substrate comprises polypropylene. 
     
     
         6 . The method according to  claim 1 , wherein the electrospinning is multi-nozzle electrospinning. 
     
     
         7 . The method according to  claim 1 , wherein the nylon fiber is nylon 6. 
     
     
         8 . The method according to  claim 1 , wherein the electrospun nylon fiber has a diameter from about 10 nm to about 100 nm. 
     
     
         9 . The method according to  claim 1 , wherein the modified copper oxide nanoparticle is functionalized with (3-glycidyloxypropyl)trimethoxysilane (GLYMO) and covalently bonded to 4-hydroxyphenylboronic acid (4-HPBA). 
     
     
         10 . The method according to  claim 1 , wherein electrospraying the modified copper oxide nanoparticle onto the surface of the nylon fiber comprises electrospraying the modified copper oxide nanoparticle onto the surface of the nylon fiber in a uniform field. 
     
     
         11 . The method according to  claim 1 , wherein the covalent bond that links the modified copper oxide nanoparticle to the nylon fiber is irreversible. 
     
     
         12 . The method according to  claim 1 , wherein one or more modified copper oxide nanoparticles are randomly oriented on the surface of the nylon fiber. 
     
     
         13 . The method according to  claim 1 , wherein the electrospraying is multi-nozzle electrospraying. 
     
     
         14 . The method according to  claim 1 , wherein the electrospinning and the electrospraying are performed simultaneously. 
     
     
         15 . The method according to  claim 1 , wherein the electrospun nylon fiber forms a single layer nanoscaffold having a thickness from about 1 μm to about 10 μm. 
     
     
         16 . The method according to  claim 1 , wherein the electrospun nylon fiber forms a multi-layer nanoscaffold. 
     
     
         17 . The method according to  claim 1 , wherein the electrospun nylon fiber forms a nanoscaffold having a pore size of about 50 nm. 
     
     
         18 . The method according to  claim 1 , wherein the composite article has a virus filtration of about 99.99%. 
     
     
         19 . A method of producing a composite article, the method comprising:
 providing a nonwoven fabric substrate having a surface; and   electrospraying a modified copper oxide nanoparticle directly onto the surface of the nonwoven fabric substrate,   wherein the nonwoven fabric substrate is a meltblown nonwoven fabric.   
     
     
         20 . A method of producing a composite article, the method comprising:
 providing a nonwoven fabric substrate having a surface; and   electrospraying a modified copper oxide nanoparticle directly onto the surface of the nonwoven fabric substrate,   wherein the nonwoven fabric substrate is a spunbond nonwoven fabric.